Completely replacing the C and D-pillar side wall

AR63.10-P-0800FA

Completely replacing the C and D-pillar side wall

19.6.96



Removing



General information on repairs to body

All models

AH60.00-N-0001-01A



Guidelines for removing fuel tank when performing welding work on bodies

AH60.00-P-3000-01Z

 Danger!

Risk of explosion as fuel vapors can ignite. Risk of poisoning from inhaling fuel vapors and exposed handling of fuel. Risk of injury if fuel splashes hit the eyes.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Remove fuel tank

AR47.10-P-4100BA

2

Remove detachable parts in area to be repaired

3

Cover all detachable body components remaining in vehicle (area to be repaired)

4

Set up straightening bench with module members and straightening set

Pay attention to the arrangement drawings enclosed with the straightening angle set.

Celette straightening set

*WE58.40-Z-1003-01A

Car-Bench straightening set

*WE58.40-Z-1002-01A

Model 210.281/282

Use additional supplementary straightening set! Refer to

Celette supplementary straightening set

*WE58.40-Z-1008-01A

Car-Bench supplementary straightening set

*WE58.40-Z-1009-01A

Set-up of Celette straightening bracket set

AR60.10-P-1070F

5

Set vehicle onto straightening bench using two-column lift and fasten

6

Separate rear fender

AR63.50-P-1400-02FA

 Spot weld milling cutter

*201589005100

Left-hand side

*210589092300

 on right side

*210589102300

7

Separate inner C and D-pillar side wall

AR63.10-P-0800-01FA

 Spot weld milling cutter

*201589005100

8

Prepare inner C and D-pillar side wall

AR63.10-P-0800-02FA

9

Install side portal straightening set

 Set up sequence

AR60.20-P-1700F

Set up sequence of portal bracket set for B and C-pillars

AR60.20-P-1700-06F

 Set of check and welding gauges

*210589042300

 Side portal frame

*210589172300



Installing

 Danger!

Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of highly inflammable materials. Injury hazard from welding spatter and UV-light while welding. Risk of poisoning caused by inhaling welding vapors.

Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor.

AS00.00-Z-0007-01A



Measures for preventing damage to vehicles or components when performing arc welding work

All models

AH00.00-N-0005-01A

10

Install side wall on C-pillar on inside and weld in

AR63.10-P-0800-04FA

11

Install side wall on D-pillar on inside and weld in

AR63.10-P-0800-05FA

12

Prepare new rear fender part

AR63.50-P-1400-03FA

13

Install rear fender and weld in

During this repair, the rear fender is installed and welded in completely according to the replacement part.

AR63.50-P-1400-04FA

 Left-hand side

*210589182300

Right-hand side

*210589192300

 Bending iron

*129589002700

 Feeler gauge

*129589032100

14

Clean areas to be repaired and prime with priming filler

Notes on paintwork repairs

AH98.00-P-9408-02A

15

Supplement standard seals with MB body sealant

AR97.10-P-4000F

16

Supplement standard underbody protection with MB permanent underbody sealant

AR97.20-P-0500-03A

17

Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408-02A

18

Apply additional cavity preservation

AP97.20-P-0640A

19

Reinstall all removed assembly parts

Number

Designation

WH58.30-Z-1002-01A

Ball cutter, dia. 12 mm

WH58.30-Z-1003-01A

Electrode miller

WH58.30-Z-1006-01A

Vario Drill WS 91 spot weld removing tool

WH58.30-Z-1002-02A

Hole punching pliers, dia. 7 mm

WH58.30-Z-1003-02A

Clamping pliers

WH58.30-Z-1031-02A

C-clamp

WH58.30-Z-1001-03A

Round wire brush, braided, dia. 70 mm

WH58.30-Z-1021-04A

Cutting disk, dia. 65 mm, 80 m/s (max. 23,500 rpm)

WH58.30-Z-1024-04A

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

WH58.30-Z-1001-40A

Tarp (fire-resistant)

WE58.40-Z-1002-01A

Car bench straightening bracket set 82417, (model 210)

WE58.40-Z-1003-01A

Celette straightening bracket set 7210.300 (model 210)

WE58.40-Z-1008-01A

Celette straightening bracket set 7210.307 (model 210, 4-Matic ), as supplement to 7210.300, (model 210)

WE58.40-Z-1009-01A

Car-Bench straightening bracket set 82 422 (model 210, 4-Matic ), as supplement to 82417, (model 210)

WE58.40-Z-1001-01E

Celette straightening bench

WE58.40-Z-1002-01E

Celette straightening unit

WE58.40-Z-1003-01E

Car-Bench straightening bench

WE58.40-Z-1004-01E

Car-Bench straightening lifting platform

WE58.40-Z-1005-01E

Car-Bench straightening equipment

WE58.40-Z-1007-01E

Celette module crossmember set 955.940

WE58.40-Z-1011-01E

Car-Bench Universal crossmember set A 296/15 (all crossmembers 1500 mm long)

WE58.40-Z-1001-02A

Inert gas welder

WE58.40-Z-1002-02A

Spot welder

WE58.40-Z-1001-03A

Drill (electric/pneumatic)

WE58.40-Z-1002-03A

Straight grinder (electric/pneumatic)

WE58.40-Z-1003-03A

Angle grinder (electric/pneumatic)

WE58.40-Z-1004-03A

Body saw (electric/pneumatic)

WE58.40-Z-1005-03A

Wet/dry vacuum cleaner

WE58.40-Z-1001-05A

Two-post lifting platform